Liquid crystal panel, liquid crystal panel fabrication method, liquid crystal panel fabrication apparatus, and polarizing plate sticking apparatus

ABSTRACT

A liquid crystal fabrication method includes the steps of: dropping liquid crystal on a first substrate at an upper surface inside regions enclosed by a sealing agent disposed thereon; overlaying a second substrate on the first substrate downward to stick the substrates together; sticking a polarizing plate on an upper surface of the first and second substrates; and collectively dividing the first and second substrates and the polarizing plate.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of co-pending U.S.application Ser. No. 10/472,723, filed Sep. 18, 2003, which was aNational Stage Filing of PCT Application No. PCT/JP02/12140, filed Nov.20, 2002, the teachings of all being incorporated herein by reference intheir entirely.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to liquid crystal panels (also referred toas “liquid crystal display panels”), methods of fabricating the same,and apparatuses used to fabricate the same. Furthermore, the presentinvention relates to apparatuses used to stick a polarizing plate andparticularly to apparatuses used in a liquid crystal panel fabricationprocess to stick a polarizing plate that is supplied in a roll.

2. Description of the Background Art

In general a liquid crystal panel has a structure formed of two glasssubstrates stacked one on the other in parallel and stuck together witha predetermined small gap posed therebetween and filled with liquidcrystal. As a method of fabricating such a crystal panel, aconventional, general method will be described with reference to FIGS.44-49. As shown in FIG. 44, when a thin film transistor (TFT) glasssubstrate 101 and a color filter (CF) glass substrate 102 are to bestuck together, a sealing agent 103 is arranged on one of thesubstrates. In the FIG. 44 example, TFT glass substrate 101 has asurface with sealing agent 103 adhesively fixed thereon. Sealing agent103 is arranged in a frame to define a region to serve as a spaceconfining liquid crystal (hereinafter referred to as a “liquid crystalcell”). It is, however, not completely closed. As shown in FIG. 44, ithas an opening to serve as an inlet 116. TFT and CF glass substrates 101and 102 are substrates having a large size allowing a plurality ofcrystal panels to be provided therefrom, and on the substrate aplurality of sealing agents 103 are arranged. Sealing agent 103 isthermosetting resin or the like.

TFT and CF glass substrates 101 and 102 are stuck together by sealingagent 103 and heated to allow sealing agent 103 to set to provide alarge format substrate formed of the stuck substrates. TFT and CF glasssubstrates 101 and 102 are then divided for each individual regionsurrounded by sealing agent 103. Thus, as shown in FIG. 45, a substrateformed of substrates stuck together 114 and including a liquid crystalcell 115 is obtained. The substrate formed of substrates stuck together114 is accommodated in a vacuum apparatus and liquid crystal cell 115has its interior and exterior both vacuumed. Then, as shown in FIG. 46,inlet 116 defined by an opening of sealing agent 103 is immersed inliquid crystal 104 and the vacuum apparatus's internal atmosphere isgradually returned to atmospheric pressure. By a difference in pressurebetween the interior and exterior of liquid crystal cell 115, andcapillarity, liquid crystal 104 is introduced into liquid crystal cell115. Liquid crystal cell 115 is thus filled with liquid crystal 104.Subsequently, sealing resin 105, ultraviolet ray curing resin, isapplied to inlet 116. Ultraviolet radiation is provided to illuminatesealing resin 105 to allow it to set to seal liquid crystal 104 inliquid crystal cell 115 to obtain the substrate formed of substratesstuck together 114, as shown in FIG. 47.

The substrate formed of substrates stuck together 114 is structured forexample to have one side with a terminal portion (not shown) exposed. Tothis terminal portion a probe pin is connected, and an inspection isconducted. If the inspection does not reveal any abnormality, apolarizing plate 106 supplied in a sheet in a size corresponding to thesubstrate formed of substrates stuck together 114 is stuck on one oropposite sides of panel 114, as shown in FIG. 48. A liquid crystal panel140 is thus obtained.

The conventional liquid crystal panel fabrication method is representedin a flow chart, as shown in FIG. 49. In FIG. 49, at the step ofsticking a polarizing plate a liquid crystal panel is completed. Notethat FIG. 49 also shows a process performed after the liquid crystalpanel is completed. More specifically, by connecting a flexible printedcircuit (FPC) to a terminal portion of the liquid crystal panel andattaching a backlight and a case, a liquid crystal display device isobtained.

However, the polarizing plate must be stuck slowly to prevent generationof static electricity. For example, sticking a single plate requires atime of approximately 8 to 10 seconds. In particular, a small sizeliquid crystal panel used for example in mobile phones is produced bydividing a single, large format glass substrate to provide severalhundreds of liquid crystal panels. In that case, such a conventional artas described above requires a significantly increased number ofoperations in the steps for example of sticking the polarizing plate,conducting an inspection, and the like, which is significantly timeconsuming.

This disadvantage may be addressed, as disclosed in Japanese PatentLaying-Open No. 6-342139, by sticking a polarizing plate on an elongatesubstrate provided with regions arranged in a row to serve as cells, andthen dividing the same for each cell. This method does provide a reducedcycle time for the step of sticking the polarizing plate (a reduced timerequired for the step of sticking the polarizing plate for a singleliquid crystal panel). In recent years, however, a single large formatglass substrate has also been used to produce several hundreds of liquidcrystal panels, and in such a case the method employing the elongatesubstrate as described above does not provide a cycle time sufficientlyeffectively reduced.

Conventionally when a glass substrate of large size is used to produceliquid crystal panels of medium or small size the glass substrate hasbeen divided into small pieces to form discrete cells and a polarizingplate has been stuck on each cell. This approach, however, requiressticking a polarizing plate on each single cell and also when theinfluence of static electricity is considered the apparatus cannotsimply be rapidly operated. As such, to stick a single polarizing plateon one side of the cell, a time of approximately eight to ten secondswould be required. In addition, the substrate having been dividedprovides a large number of cells and a large number of apparatuses isaccordingly required. As such it is desirable that in a condition withas many as cells included, collectively a polarizing plate is stuckthereon and then divided to achieve a significantly reduced cycle timeof the step of sticking the polarizing plate.

More specifically, it is significantly effective if a collectivepolarizing plate can be stuck for example on a glass substrate dividedin an elongate geometry to facilitate the step of introducing liquidcrystal, a large size substrate formed by introducing liquid crystal indroplets and sticking substrates together, or a similar substrate. Forexample from a glass substrate having a side of 600 to 700 mm no lessthan 200 cells can be obtained, and when a polarizing plate is stuck onthe glass substrate having a side of 600 to 700 mm it can be stuckthereon with efficiency increased by approximately double digitsdramatically. Normally, a polarizing plate to be stuck on cells ispreviously cut in a form matching a single cell, and thereafterundergoes an inspection, one by one. As such the component costssignificantly. If a polarizing plate supplied in a roll can be stuck oncells, not only can an inspection of discrete cells be eliminated butthe dust that is caused when a substrate is cut into pieces can also beprevented.

Conventionally a rolled polarizing plate has been stuck on a glasssubstrate for example as disclosed in Japanese Patent Laying-Open No.60-192914. Furthermore, an elongate polarizing plate has been stuck on aglass substrate by a method for example as disclosed in Japanese PatentLaying-Open No. 1-260417.

Japanese Patent Laying-Open No. 60-192914 discloses that a rolledpolarizing plate is unrolled and a liquid crystal display panel is stuckdirectly thereon and subsequently the polarizing plate is cut. With thismethod, however, the polarizing plate has a large portion wasted.Furthermore, a portion unnecessary as a liquid crystal panel would alsohave a polarizing plate stuck thereon, which renders it difficult toperform a subsequent division step. To produce a transmission liquidcrystal display device, in particular, it is necessary that a liquidcrystal panel has opposite sides with a polarizing plate stuck thereon.The axes of polarization are orthogonal to each other and if thepolarizing plate is large a marker (a reference for a division step toprovide cells) provided in a glass substrate cannot be read.

Furthermore in such a configuration as disclosed in Japanese PatentLaying-Open No. 1-260417 if the substrate and the polarizing plate areof large size a pneumatic chuck mechanism moving the elongate polarizingplate and a press for half-cutting are spaced wide apart andconsequently the apparatus itself would have a significantly increasedsize disadvantageously.

Furthermore, the apparatus described in Japanese Patent Laying-Open No.1-260417 cuts a polarizing plate first in a strip and then in a size inaccordance with a liquid crystal display device. The polarizing plateneeds to be cut twice and the apparatus is accordingly required to havean increased size disadvantageously.

SUMMARY OF THE INVENTION

A first object of the present invention is to reduce a period of timerequired to produce a single liquid crystal panel when a large number ofsuch liquid crystal panels are collectively produced.

A second object of the present invention is to provide an apparatus thatcan stick a polarizing plate on a substrate at a desired portion with areduced number of steps and hence more efficiently.

To achieve the first object the present invention in one aspect providesa liquid crystal panel including: a first substrate; a second substrateoverlapping the first substrate with a liquid crystal layer posedtherebetween; a sealing agent disposed between the first and secondsubstrates to surround the liquid crystal layer; and a polarizing platestuck on at least one of the first and second substrates at a surfaceopposite the liquid crystal layer. The polarizing plate has an endreceding from an end of one substrate and having a surface inclined.Alternatively, the present invention in another aspect provides a liquidcrystal panel including: a first substrate; a second substrateoverlapping the first substrate with a liquid crystal layer posedtherebetween; a sealing agent disposed between the first substrate andthe second substrate to surround the liquid crystal layer; and apolarizing plate stuck on at least one of the first and secondsubstrates at a surface opposite the liquid crystal layer, wherein thepolarizing plate has an end receding from an end of one substrate, andat the polarizing plate's end, glue bonding the polarizing plate and thesubstrate together is exposed and extends in a direction. Thus thepolarizing plate is stuck collectively on a large format substrateformed of substrates stuck together and then along a line to be followedfor division the polarizing plate is scraped off and then the substrateis provided with a crack and divided into individual liquid crystalpanels. The liquid crystal panels can be fabricated effectively.

In the present invention preferably the sealing agent continuouslysurrounds an entire perimeter of the liquid crystal layer. As such, alarge format substrate having a surface previously provided with asealing agent forming an enclosure that has received liquid crystaldropped therein and another substrate can be stuck together tocollectively fabricate a plurality of liquid crystal cells to provide anefficiently producible liquid crystal panel.

In the present invention preferably the first substrate has a terminalportion protruding outer than the second substrate. The first substratehas a surface with the polarizing plate stuck thereon. The polarizingplate also extends on a back side of the terminal portion. Thus thepolarizing plate is stuck collectively on a large format substrateformed of substrates stuck together and then along a line to be followedfor division the polarizing plate is scraped off and then the substrateis provided with a crack and divided into individual liquid crystalpanels. The liquid crystal panels can be fabricated effectively.

In the present invention preferably the first substrate has a terminalportion projecting outer than the second substrate, the first substrateat a display area and the terminal portion has a polarizing plate stuckthereon, and the first substrate between the display area and theterminal portion has a region free of the polarizing plate.

To achieve the first object the present invention provides a method offabricating a liquid crystal panel, including the steps of placing asealing agent on a surface of a first substrate in a form of anenclosure; introducing liquid crystal on the first substrate in a regionenclosed by the sealing agent or on a second substrate in a regioncorresponding to the region located on the first substrate enclosed bythe sealing agent; sticking the first substrate and the second substratetogether to form a substrate formed of the first substrate and thesecond substrate; sticking a polarizing plate on at least one of thefirst substrate and the second substrate; and dividing the substrate tohave a geometry providing a plurality of liquid crystal panels. Inaccordance with the present invention in fabricating a liquid crystalcell and sticking a polarizing plate a large format substrate includinga plurality of liquid crystal cells can exactly be used to collectivelydo so. Liquid crystal cells can effectively be produced.

In the present invention preferably in the step of dividing, at leastone of the first substrate and the second substrate has the polarizingplate partially removed to allow the substrate to have a surface exposedand the first substrate and the second substrate are then divided. Thiscan prevents the substrate from cracking at an undesired position andthe polarizing plate from undesirably peeling off. The substrate canefficiently and accurately be divided into individual crystal panels.

In the present invention preferably the step of dividing is preceded bythe step of collectively inspecting liquid crystal cells defined by thesealing agent, via an interconnection electrically connected to eachliquid crystal cell for inspection. Conventionally, individual liquidcrystal panels are each inspected. In the present invention, a pluralityof liquid crystal panels can collectively, simultaneously be inspected.This can provide a reduced inspection time required per liquid crystalpanel.

In the present invention preferably the step of inspecting is performedafter the step of overlaying and before the step of sticking.

In the present invention preferably the step of inspecting is performedafter the step of sticking.

In the present invention preferably there is included the step ofexposing a terminal portion provided at the first substrate. This allowsa terminal to be exposed at the terminal portion so that from thisterminal a signal for an inspection can be supplied so as to facilitatethe inspection.

In the present invention preferably the step of exposing is performed inthe step of overlaying by displacing the substrates from each other. Aterminal portion can be exposed without dividing the substrate.

In the present invention preferably the step of exposing is performedafter the step of overlaying by dividing and partially removing one ofthe substrates. This ensures that if substrates of the same size arestuck together the terminal portion can be exposed at a desiredposition.

To achieve the first object the present invention provides a liquidcrystal panel fabrication apparatus including: means for placing asealing agent on a surface of a first substrate in a form of anenclosure; means for introducing liquid crystal on the first substratein a region enclosed by the sealing agent or on a second substrate in aregion corresponding to the region located on the first substrateenclosed by the sealing agent; means for sticking the first substrateand the second substrate together to form a substrate formed of thefirst substrate and the second substrate; means for sticking apolarizing plate on at least one of the first substrate and the secondsubstrate; and means for dividing the substrate formed of the first andsecond substrates to have a geometry providing a plurality of liquidcrystal panels. Substrates of a large format can collectively be stucktogether to form a substrate formed of the stuck substrates andincluding a plurality of liquid crystal cells and a polarizing plate cancollectively be stuck thereon so that a large number of liquid crystalcells can efficiently be produced.

To achieve the second object the present invention provides an apparatussticking a polarizing plate, including: means holding a roll of apolarizing plate formed in a strip; means cutting in a geometry of aliquid crystal substrate the polarizing plate continuously extractedfrom the roll; and means sticking on the liquid crystal substrate thepolarizing plate cut. The apparatus thus configured extracts apolarizing plate in the form of a strip continuously extracted from aroll and cuts the polarizing plate in the geometry of a liquid crystalsubstrate. This cut substrate is stuck on the liquid crystal substrateby the sticking means so that from the polarizing plate in the form ofthe strip a polarizing plate that follows the liquid crystal substratecan immediately be obtained. As the cut polarizing plate can immediatelybe stuck on the liquid crystal substrate at a desired portion, thepolarizing plate can be stuck on the substrate significantly moreefficiently.

Still preferably the roll is a roll of a combination of a support andthe polarizing plate overlying the support, and the means cutting doesnot cut the support in cutting the polarizing plate.

Still preferably the apparatus sticking the polarizing plate furtherincludes means detecting an axis of polarization of the polarizing plateunrolled. The means cutting is driven by a direction of an axis ofpolarization detected by the detection means to adjust a directionfollowed to cut the polarizing plate. As such, the polarizing plate canbe cut in accordance with the direction of the axis of polarization sothat the direction of the axis of polarization of the cut polarizingplate can be recognized. As a result, a high quality liquid crystaldisplay device allowing a direction of an axis of polarization to becontrolled with precision can be provided.

Still preferably the means cutting cuts the polarizing plate to have asize substantially equal to that of the liquid crystal substrate. Stillpreferably the means cutting includes press means. Still preferably themeans cutting includes a linear blade. Still preferably the linear bladeis attached to the means sticking.

The foregoing and other objects, features, aspects and advantages of thepresent invention will become more apparent from the following detaileddescription of the present invention when taken in conjunction with theaccompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawing:

FIG. 1 is a first illustration of a method of fabricating a liquidcrystal panel in accordance with the present invention in a firstembodiment;

FIG. 2 is a partial, plan view of the liquid crystal panel in accordancewith the present invention in the first embodiment;

FIG. 3 is a partial cross section of the liquid crystal panel inaccordance with the present invention in the first embodiment;

FIG. 4 is a second illustration of the method fabricating the liquidcrystal panel in accordance with the present invention in the firstembodiment;

FIG. 5 illustrates equipment for performing the step of sticking apolarizing plate that is employed in the method of fabricating theliquid crystal panel in accordance with the present invention in thefirst embodiment;

FIG. 6 illustrates a first method of exposing a terminal portion forinspection in the method of fabricating the liquid crystal panel inaccordance with the present invention in the first embodiment;

FIG. 7 is a plan view of substrates stuck together, as obtained in thecourse of the method of fabricating the liquid crystal panel inaccordance with the present invention in the first embodiment;

FIG. 8 illustrates a second method of exposing a terminal portion forinspection in the method of fabricating the liquid crystal panel inaccordance with the present invention in the first embodiment;

FIG. 9 illustrates a third method of exposing a terminal portion forinspection in the method of fabricating the liquid crystal panel inaccordance with the present invention in the first embodiment;

FIG. 10 illustrates equipment for performing the step of dividing thatis employed in the method of fabricating the liquid crystal panel inaccordance with the present invention in the first embodiment;

FIG. 11 is a perspective view of a first exemplary blade used in themethod of fabricating the liquid crystal panel in accordance with thepresent invention in the first embodiment;

FIG. 12 is a perspective view of a second exemplary blade used in themethod of fabricating the liquid crystal panel in accordance with thepresent invention in the first embodiment;

FIG. 13 is a side view of a wheel cutter used in the method offabricating the liquid crystal panel in accordance with the presentinvention in the first embodiment;

FIG. 14 is a front view of the wheel cutter used in the method offabricating the liquid crystal panel in accordance with the presentinvention in the first embodiment;

FIG. 15 is a third illustration of the method fabricating the liquidcrystal panel in accordance with the present invention in the firstembodiment;

FIG. 16 is a fourth illustration of the method fabricating the liquidcrystal panel in accordance with the present invention in the firstembodiment;

FIG. 17 is a flow chart of the method of fabricating the liquid crystalpanel in accordance with the present invention in the first embodiment;

FIG. 18 is a flow chart of an exemplary variation of the method offabricating the liquid crystal panel in accordance with the presentinvention in the first embodiment;

FIG. 19 represents a concept of a liquid crystal panel fabricationapparatus in accordance with the present invention in a secondembodiment;

FIG. 20 is a side view of a liquid crystal panel in accordance with thepresent invention in a third embodiment;

FIG. 21 is a partially enlarged cross section of the liquid crystalpanel in accordance with the present invention in the third embodiment;

FIGS. 22A and 22B are views for illustrating only a single row of liquidcrystal cells undergoing an illumination test in the method offabricating a liquid crystal panel in accordance with the presentinvention in the first embodiment;

FIG. 23 is a perspective view of an end of a blade exemplarily shown inaccording with the present invention in the third embodiment;

FIG. 24 is a view for illustrating a structure in accordance with thepresent invention in the third embodiment, as provided by using a blade;

FIG. 25 is a view for illustrating a precision in accordance with thepresent invention in the third embodiment;

FIG. 26 is a side view of another example of the liquid crystal panel inaccordance with the present invention in the third embodiment;

FIG. 27 is a side view of still another example of the liquid crystalpanel in accordance with the present invention in the third embodiment;

FIGS. 28A-28C are front, side and top views, respectively, of an end ofa blade exemplarily shown in accordance with the present invention inthe third embodiment for beveling:

FIG. 29 is a view for illustrating by way of example how the blade shownin FIGS. 28A-28C is used;

FIG. 30 is a partial, perspective view of beveling in accordance withthe present invention in the third embodiment by way of examples;

FIG. 31 is a view for illustrating an order in which the blade runs inaccordance with the present invention in the third embodiment;

FIG. 32 is a plan view of an exemplary liquid crystal panel obtained bythe method of fabricating a liquid crystal panel in accordance with thepresent invention in the third embodiment;

FIGS. 33-38 are first to sixth illustrations, respectively, of how ablade is used in accordance with the present invention in the thirdembodiment;

FIG. 39 is an illustration of how a blade in a different form is used inaccordance with the present invention in the third embodiment by way ofexample;

FIG. 40 represents a concept of one embodiment of a polarizing platesticking apparatus of the present invention;

FIG. 41 is a side view of the polarizing plate sticking apparatus of thepresent invention in a fourth embodiment;

FIG. 42 is a side view of the polarizing plate sticking apparatus of thepresent invention in a fifth embodiment;

FIG. 43 is a side view of the polarizing plate sticking apparatus of thepresent invention in a sixth embodiment;

FIG. 44 is a first illustration of a method of fabricating a liquidcrystal panel in accordance with conventional art;

FIG. 45 is a plan view of substrates stuck together, as obtained in thecourse of the method of fabricating the liquid crystal panel inaccordance with the conventional art;

FIG. 46 is a second illustration of the method of fabricating the liquidcrystal panel in accordance with the conventional art;

FIG. 47 is a third illustration of the method of fabricating the liquidcrystal panel in accordance with the conventional art;

FIG. 48 is a fourth illustration of the method of fabricating the liquidcrystal panel in accordance with the conventional art; and

FIG. 49 is a flow chart of the method of fabricating the liquid crystalpanel in accordance with the conventional art.

DESCRIPTION OF THE PREFERRED EMBODIMENTS First Embodiment

Method of Fabrication

With reference to FIGS. 1-17 the present invention in a first embodimentprovides a liquid crystal panel fabrication method as will be describedhereinafter. Initially, TFT glass substrate 101 and CF glass substrate102 are stuck together. More specifically, before the substrates arestuck together, sealing agent 103 is arranged on one of the twosubstrates. Sealing agent 103 may be applied by means of a dispenserthrough a small syringe or it may be applied by screen-printing. In theFIG. 1 example, TFT glass substrate 101 has a surface having sealingagent 103 arranged thereon. Sealing agent 103 is arranged to surroundcontinuously an entire periphery of a region to be provided with aliquid crystal layer. In other words, this sealing agent 103 does nothave the opening that the conventional sealing agent 103 shown in FIG.44 does. The present invention exhibits a particularly significanteffect when a large format substrate is used to produce medium- andsmall-size liquid crystal panels therefrom in large numbers. Suchmedium- and small-size liquid crystal panels are mainly applied inmobile phones, car navigation systems and the like, which are requiredto endure temperature higher than office automation equipment, whichmainly employs a large size crystal panel. Accordingly, sealing agent103 is formed for example of heat-resistive, photo-curing resin or thelike. Alternatively, sealing agent 103 may be thermosetting resin orresin of a type set by light and heat applied together.

Common Transition Electrode

TFT and CF glass substrates 101 and 102 are both provided withelectrodes, respectively, for applying voltage to liquid crystal. When aliquid crystal panel is completed, however, desirably, a terminalportion provided only at one substrate exclusively is used to externallyextract the electrodes. Accordingly, from the substrate without theterminal to the substrate with the terminal the electrode need to beextracted. To do so, a common transition electrode is used.

The “common transition electrode” is an electrode posed between glasssubstrates opposite with a liquid crystal layer posed therebetween toallow electrical conduction between electrodes of surfaces of the glasssubstrates, respectively. Although the glass substrates before they arestuck together are large format substrates that have not yet beendivided into individual liquid crystal panels, for the sake ofillustration the substrates are divided into individual liquid crystalpanels and a portion of one such liquid crystal panel is shown in FIG.2, enlarged. Inside sealing agent 103 on glass substrate 110 a, 102 a aplurality of common electrode pads 203 are arranged having theirrespective, small, round common transition electrodes 210 arrangedtherein. From common electrode pad 203 an interconnection extends acrosssealing agent 103 toward an outer edge of the liquid crystal panel.Common transition electrode 210 is configured to include at the center asmall, round, conductive granule 209 having an external surface wrappedwith a conductive material 205.

When the substrates are stuck together, common transition electrode 210is sandwiched between upper and lower common electrode pads 203 andsquashed thereby. As a result, as shown in FIG. 3 in cross section, withconductive granule 209 interposed, upper and lower glass substrates 101a and 102 a face each other, and conductive material 205 having beensquashed and deformed surrounds conductive granule 209. Electricalconduction is thus achieved between the electrode on a surface of glass30 substrate 101 a and that on a surface of glass substrate 102 a. Notethat FIG. 3 is provided to show common transition electrode 210 squashedand as a liquid crystal panel it is a cross section in an example inconfiguration different from FIG. 2. In the present embodiment a liquidcrystal panel is fabricated by overlaying glass substrates on each otherin a vacuum and recovering the atmospheric pressure to use the pressureto stick the substrates together. With this pressure exerted, anultraviolet ray is directed or heat is applied to allow the sealingagent to set.

Step of Dropping Liquid Crystal and Step of Sticking Substrates Together

In the step of dropping liquid crystal, as shown in FIG. 1, liquidcrystal 104 is dropped on TFT glass substrate 101 inside sealing agent103 or on opposite CF glass substrate 102 at a location corresponding toinside a portion with which the sealing agent is to brought intocontact. Liquid crystal 104 is dropped by an amount matching the volumeof a cell and accumulates inside sealing agent 103. Then in the step ofsticking the substrate together glass substrate 102 is laid on grasssubstrate 101 in a vacuum and exposed for example to ultraviolet lightand heated if necessary to allow sealing agent 103 to set tohermetically seal liquid crystal 104 in the cell. Thus a large formatsubstrate 30 formed of the substrates stuck together is obtained (seeFIG. 4).

Step of Sticking a Polarizing Plate

The substrates are stuck together to obtain large format substrate 30.Substrate 30 then has a surface washed. In the step of sticking apolarizing plate, as shown in FIG. 4, a polarizing plate 106 is stuck ona surface of substrate 30. Polarizing plate 106 is supplied from a roll107 of the polarizing plate for large format substrate 30. If a liquidcrystal panel to be fabricated is of reflective type, polarizing plate106 may be stuck on one side alone of substrate 30. If the liquidcrystal panel is of transmission type, polarizing plate 106 is stuck onopposite sides of substrate 30.

Equipment used to stick the polarizing plate will be described withreference to FIG. 5 more specifically. Roll 107 of the polarizing plateis supported by a reel 361 supported by a holding means 360. Apolarizing plate 315 b is overlaid on a separator 315 c to provide acombination 315 of the two and supplied in roll 107 supplying thepolarizing plate. Initially, combination 315 is extracted from roll 107and moves past a detector 350 detecting a direction of an axis ofpolarization of polarizing plate 315 b. On a cutting stage 355 a cuttingblade 351 moves downward toward combination 315. Blade 351 does not cutseparator 315 c and only cuts polarizing plate 315 b overlying theseparator. Separator 315 c is guided by a peeling member 327 in adirection different than polarizing plate 315 b and taken up on a takeup roll 320. Polarizing plate 315 b with separator 315 c peeled offproceeds and then pressed by a guide roller 380 to move in a slightlydownward direction. A head 390 operating to stick the polarizing plateon a substrate includes a press and contact roller 390 a, a suctionplatform 390 b and a position detection sensor 390 c. Polarizing plate315 b slides on a surface of suction platform 390 b, moves past underroller 390 a and is thus guided to position detection sensor 390 c fordetection, while a polarizing plate sticking stage 310 is moved upwardto bring substrate 30 on stage 310 into contact with polarizing plate315 b. Stage 310 can be moved in a direction indicated by an arrow A tostick polarizing plate 315 b on substrate 30. Note that in accordancewith a direction of an axis of polarization detected by detector 350stage 310 can be rotated to stick polarizing plate 315 b in accordancewith a direction of an axis of polarization required for substrate 30.

Polarizing plate 315 b can be stuck only at a portion pressed by roller390 a against substrate 30 to prevent air bubbles from enteringtherebetween. While in this example polarizing plate 315 b is cut withblade 351, it may alternatively be cut by laser, which canadvantageously be used as it does not produce chips. Polarizing plate315 b that is supplied in roll 107 allows a continuous stickingoperation. Separator 315 can be peeled off polarizing plate 315 bimmediately before the polarizing plate is stuck on the substrate toprevent the polarizing plate from having a surface with dust thereon. Inthe step of sticking the polarizing plate, desirably, not only ispolarizing plate 315 b stuck on substrate 30 but thereafter to eliminateair bubbles and the like substrate 30 is also subjected to apressurization, degassing apparatus.

Furthermore the step of sticking a polarizing plate is not limited tosticking a polarizing plate fed from a role as described above. Thepolarizing plate may also be fed in the form of an optical correctionfilm cut to have substantially the same size as the substrate.Alternatively, it may be cut to have a size approximately equal to atotal area of a plurality of liquid crystal cells. Alternatively, it maybe cut to have an area larger than that of at least a single liquidcrystal cell.

Step of Exposing a Terminal Portion

In the step of exposing a terminal portion, an inspection terminalportion 130 is exposed at an end of large format substrate 30 formed ofsubstrates stuck together. Inspection terminal portion 130 is a regioncorresponding to a protrusion of one of the two glass substrates. Ininspection terminal portion 130 an inspection terminal 131 is arranged.Inspection terminal portion 130 is exposed by a method, as follows:initially, as shown in FIG. 6, one of the glass substrates that is notprovided with inspection terminal 131 is sized to be smaller than theother that is provided with inspection terminal 131 and the glasssubstrates are superimposed on each other. As shown in FIG. 7, frominspection terminal 131 an inspection interconnection 132 extends towardeach liquid crystal cell 115 included in substrate 30. Note thatinspection terminals 131 is not limited in number, position or the liketo the FIG. 7 example.

Inspection terminal portion 130 can be exposed by another method. Asshown in FIG. 8, substrate 30 formed of two substrates stuck togetherhas an end having only one substrate cut off and removed. Inspectionterminal portion 130 can be exposed by still another method. As shown inFIG. 9, the substrates are offset and stuck together to exposeinspection terminal portion 130. For the first and third methods thestep of exposing the terminal portion will be included in the step ofsticking the substrates together.

Step of Collective Inspection

Then, in the step of collective inspection, a probe pin is connected toinspection terminal 131 exposed and a drive signal for an illuminationtest is supplied to cause liquid crystal cells 115 in substrate 30 tocollectively illuminate. Since this test is conducted with large formatsubstrate 30, portions corresponding to a plurality of liquid crystalpanels can be inspected at a time. By applying the drive signal for theillumination test, a defective pixel, a point defect, and an unevenindication can be found. When liquid crystal cell 115 is found to bedefective, information thereof is supplied to a production managementsystem by a computer to prevent the process from proceeding with thesubsequent step to further perform an operation uselessly.

In the step of the collection inspection, liquid crystal cell 115located at a center of large format substrate 30 is distant frominspection terminal 131 and may suffer a delay of the signal, ascompared with liquid crystal cell 115 located at a periphery ofsubstrate 30. To prevent this, desirably at a portion directed to liquidcrystal cell 115 distant from inspection terminal 131 inspectioninterconnection 132 has a bus line with an increased width.

While in the present description the step of collective inspectioncauses all of the liquid crystal cells included in large formatsubstrate 30 to illuminate for inspection, if it is sufficient to detectonly a significant defect then only a single row of liquid crystal cellsmay be illuminated. In that case, as shown in FIGS. 22A and 22B, largeformat substrate 30 has exposed an inspection terminal portion 117, aregion at which terminals corresponding to all of the liquid crystalcells 115 of a single row or column arranged along any one of outermostsides, are collected. A probe pin is brought into contact withinspection terminal portion 117. Thus a single row or column of liquidcrystal cells 115 alone can be subjected to the illumination test.

Step of Division

Then, in the step of division, substrate 30 is divided in a size ofindividual liquid crystal panels. In this division step, the two glasssubstrate stuck together and polarizing plate 106 stuck on a surfacethereof are collectively divided. As a result, each liquid crystal panelis divided for each liquid crystal cell 115.

Equipment used to perform the division step will be described withreference to FIG. 10 more specifically. A movable unit 410 includes acutting mechanism 460 at a front side and a wheel cutter 430 at a rearside, as seen in a direction B, in which the unit moves. Movable unit410 moves along a space between liquid crystal cells 115 arranged inlarge format substrate 30 (see FIG. 7). As the unit moves, polarizingplate 106 is cut away by a blade 461. As blade 461, a blade having sucha form as a curving knife as shown in FIGS. 11 and 12 is usable.

Furthermore, preferably blade 461 may be held at a portion provided witha heating means (not shown) to heat blade 461. As blade 461 transmitsheat, a glue layer bonding polarizing plate 106 and glass substrate 102together softens to also help to peel the plate off the glass surface.This effect is particularly increased when blade 461 runs slow.Furthermore, while typically the blade may be heated to approximately 50to 70° C., the optimal temperature is determined by the type of thepolarizing plate's glue layer and thus not limited to the above range oftemperature.

After blade 461 has cut away polarizing plate 106, glass substrate 102is exposed in a strip which forms a strip region 411. Blade 461 cuttingpolarizing plate 106 produces a chip 402 a, which is removed along blade461. The equipment that employs such cutting mechanism 460 can readilyform strip region 411. Furthermore to form strip region 411 to have adesired width an identical blade or a blade having an identical geometrymay be run more than once. This allows the strip region to have a widthlarger than that of the blade.

Wheel cutter 430 forms a crack in the glass substrate for dividing thesubstrate. It has a geometry, as specifically shown in FIGS. 13 and 14.Wheel cutter 430 has a diameter d1 of approximately 2 to 3 mm to ensurethat the cutter has strength, and its cutting edge has an angle θ1 of anobtuse angle of approximately 120° to 150° to consider lifetime. Wheelcutter 430 is supported by movable unit 410 via an air cylinder (notshown) to apply a predetermined force against the glass substrate. Adistance sensor 440 is a contact sensor detecting a position of an uppersurface of polarizing plate 106. By utilizing distance sensor 440,movable unit 410 is controlled to invariably maintain a distance betweencutting mechanism 460 and wheel cutter 430, and an upper surface ofpolarizing plate 106. Distance sensor 440 is not limited to a contactsensor and it may be a non-contact sensor. Furthermore, a wheel unit ora cutter unit may be provided with a pressure-sensitive switch toconfirm that it contacts the glass substrate.

Along strip region 411 formed by blade 461 wheel cutter 430 moves toform a crack 412 for division. In strip region 411 crack 412 is formed,as shown in FIG. 15, enlarged.

While the FIGS. 10 and 15 example show that glass substrate 102 isdivided, substrate 30, formed of glass substrates 101, 102 stucktogether, has front and rear surfaces both subjected to an operation bymovable unit 410. In this condition when substrate 30 is subjected tomechanical strength, glass substrates 101, 102 are readily divided, orwithout any mechanical strength when the glass substrate have a surfacescanned by wheel cutter 430 the substrate may be divided of themselvesalong crack 412. When such equipment is used to divide large formatsubstrate 30, the glass substrates does not crack at an undesiredposition nor does polarizing plate 106 peel off undesirably so that asshown in FIG. 16, the substrate can efficiently and accurately bedivided into individual liquid crystal panels 150. While the FIG. 16example shows only eight liquid crystal panels 150, the number of thepanels is not limited to eight and can be set as appropriate. Forexample the substrate may be divided into several hundreds of panels.

In the FIG. 10 example, blade 461 for peeling off the polarizing plateand wheel cutter 430, which will be described more specificallyhereinafter, for introducing a crack in the glass substrate are providedin a single movable unit 410. Alternatively, a mechanism for peeling offthe polarizing plate and that for introducing a crack may be provided asseparate movable units.

In the above example the polarizing plate is removed by a blade.Alternatively, it may be removed by a laser. Furthermore, the wheel usedto divide the glass substrate may also be replaced with the laser. Thusthe laser can provide the both functions. Furthermore, the polarizingplate may be removed and the glass substrate divided by using anappropriate technique other than the laser.

Alternatively, large format substrate formed of substrates stucktogether 30 may have removed only a portion of the polarizing plate thatcorresponds to each liquid crystal panel's boundary, so that thepolarizing plate is divided into a plurality of polarizing platesarranged on a surface of large format substrate 30 and corresponding tothe liquid crystal panels, respectively, and thereafter large formatsubstrate 30 may be divided to obtain individual liquid crystal panels150. If this approach is employed, large format substrate 30 caninitially be divided into strips rather than individual liquid crystalpanels 150 so that liquid crystal cells can undergo an illuminationinspection by the strip.

Function and Effect

The liquid crystal panel fabrication method in the present embodiment isrepresented in a flow chart, as shown in FIG. 17. In FIG. 17, theprocess through to the division step provides a complete liquid crystalpanel. Note that FIG. 17 also shows a process performed after a liquidcrystal panel is completed. More specifically, a flexible printedcircuit (FPC) is connected to a terminal portion of the liquid crystalpanel and a backlight and a case are attached to obtain a liquid crystaldisplay device. In the conventional method (see FIG. 31) the substrateis divided at an earlier stage. Accordingly, a large number of stepsneed to be performed for each individual liquid crystal panel. In thepresent liquid crystal panel fabrication method, the larger number ofsteps can be performed for a large format substrate that is not yetdivided. This allows a liquid crystal panel and hence a liquid crystaldisplay device to be produced significantly more efficiently. This canprovide a significantly reduced time required per liquid crystal panel.

While in the above described fabrication method, as shown in FIG. 17,the step of sticking the polarizing plate is followed by an illuminationtest corresponding to the collective inspection step, the collectiveinspection step may precede the step of sticking the polarizing plate,as shown in FIG. 18. In that case, desirably, after the collectiveinspection step and before the step of sticking the polarizing plate awashing step is again performed. Alternatively, in some case, the liquidcrystal panel may be completed without performing the collectiveinspection step.

If the step of exposing the terminal is dividing and partially removinga glass substrate, as shown in FIG. 8, then in any of the systems ofFIGS. 17 and 18, a washing step needs to be included after the step ofexposing the terminal and before the step of sticking the polarizingplate.

Note that in any of the systems of FIGS. 17 and 18, desirably a washingstep is performed after the division as the division step and before theconnection of the FPC. The division step may rely on any otherappropriate method than that described with reference to FIG. 10.

Second Embodiment

Fabrication Apparatus

Reference will now be made to FIG. 19 to describe a liquid crystal panelfabrication apparatus in accordance with the present invention. Thisapparatus includes a liquid crystal dropping portion 191, a substratesticking portion 192, a polarizing plate sticking portion 193, and adividing portion 194. Each portion is arranged to be able to operate inliaison with each other. Each portion is not required to be a discreteexistence and partial or entire apparatus may serve as more than one ofthe portions described above. When the apparatus is supplied with alarge format glass substrate, liquid crystal dropping portion 191performs the step of dropping liquid crystal, substrate sticking portion192 performs the step of sticking substrates together to provide a largeformat substrate formed of the substrates stuck together with aplurality of liquid crystal cells therebetween. Furthermore thesubstrate formed of the substrate stuck together is subjected bypolarizing plate sticking portion 193 to the step of sticking apolarizing plate. This step is also performed on the large formatsubstrate. Then at dividing portion 194 the large format substrateformed of the stuck substrates is divided into individual liquid crystalpanels. This liquid crystal panel fabrication apparatus may includeother than each portion described above a collective inspection portionand a washing portion, as appropriate, in accordance with the concept ofthe liquid crystal panel fabrication method described in the firstembodiment.

Third Embodiment

Liquid Crystal Panel

Reference will be made to FIGS. 20 and 21 to describe a configuration ofa liquid crystal panel in accordance with the present invention in athird embodiment. This liquid crystal panel 150 in a side view is shownin FIG. 20. In the figure, thickness is represented exaggerated for thesake of illustration. A liquid crystal cell (not shown) is sandwiched byglass substrates 101 a, 102 a obtained by dividing glass substrates 101,102. A polarizing plate 106 a is stuck on a side of glass substrate 101a, 102 a that is opposite the liquid crystal layer, i.e., on each outersurface. Inherently there is a small gap between glass substrates 101 aand 102 a and in that gap a liquid crystal layer, a sealing agent andvarious types of electrodes are arranged, although in FIG. 20 the gap isnot shown.

FIG. 21 is an enlarged cross section of an end of liquid crystal panel150 and therearound. Polarizing plate 106 a has an end receding from anend of each glass substrate 101 a, 102 a and having an inclination. Thisis attributed to the division step using the equipment shown in FIG. 10to produce liquid crystal panel 150. As shown in FIG. 15, strip region411 exposing a surface of the glass substrate is formed, and withpolarizing plate 106 having an end surface with an inclination the glasssubstrates are divided. Accordingly, polarizing plate 106 a has an endformed as described above (see FIG. 21).

Furthermore a blade that is formed in a horseshoe, as shown in FIG. 23,can prevent the polarizing plate from having an end surface inclined. Inthat case, in the present invention, with the polarizing plate stuck andthereafter partially removed, a unique trace results. When a blade isused, the blade leaves its race in a vicinity of an end surface of thepolarizing plate along an arrow B shown in FIG. 34. For example, as theblade passes, glass substrate 102 has a surface exposed with a trace 413thereon resulting from the polarizing plate 106 glue layer drawn. If alaser rather than a blade is used to remove the polarizing plate, therewill be left a trace of temporary meltage of an end surface of thepolarizing plate.

When this method is employed for division to provide a liquid crystalpanel, a blade or laser used to remove the polarizing plate and a wheelused to divide the glass substrate that are mounted in a single movableunit 410 and thus coaxially run allow glass substrate 102 and polarizingplate 106 to have their respective end surfaces spaced by a distancemaintained constantly with the same precision as that for dividing glasssubstrate 102, i.e., for example approximately ±50 μm, as shown in FIG.25. For example, as an index representing a precision of a distance fromthree sides of polarizing plate 106 to those of glass substrate 102,|X-Y′|, |Y-Y′| and |Y1-Y1′| can all be limited to no more than 100 μm.In conventional fabrication method, the polarizing plate's geometricalerror, a sticking error, and the glass substrate's geometrical error arecombined together and thus have an effect. As such, it is difficult toprovide enhanced precision of a distance from the glass substrate's endsurface to the polarizing plate's end surface. In accordance with thepresent invention, a liquid crystal panel can be fabricated constantlywith high precision.

Furthermore, if a blade 462 such as shown in FIGS. 28A-28C is used topeel off polarizing plate 106 in a strip as shown in FIG. 29, polarizingplate 106 is initially lifted and thus peeled off glass substrate 102off and then cut by a cutting edge of the blade sandwiching oppositesides thereof. As polarizing plate 106 is initially lifted off and thenhas opposite sides cut, as shown in FIG. 30, in the region of an outlet470 as polarizing plate 106 has a center portion lifted by blade 462 aportion thereof having opposite sides still uncut will be torn bytensile strength before it is cut by the blade. As a result, as shown inFIG. 30, a beveled geometry can be obtained, as seen from above. Forexample, as shown in FIG. 31, when a blade 426 runs in an order of C1,C2, D1 and D2, polarizing plate 106 remaining on glass substrate 102 canhave a beveled geometry and an individual liquid crystal panel 151 canbe obtained as shown in FIG. 32. Thus beveling polarizing plate 106 ofliquid crystal panel 151 can prevent polarizing plate 106 from readilypeeling off glass substrate 102 in a subsequent step.

This beveling process may be adjusted in degree by adjusting the blade'sposition when it runs to change an angle ∠YOA, as shown in FIGS. 33-35.Alternatively, while a blade when it runs has a fixed position, theblade may have geometry adjusted as shown in FIGS. 36-38 to change anangle ∠YOB. If such conditions as shown in FIGS. 33 and 36 aresatisfied, the polarizing plate is peeled off after it has oppositesides cut, as shown in FIG. 39. As such, outlet 470 (see FIG. 30) doesnot have polarizing plate 106 ruptured and hence beveled. If suchconditions as shown in FIGS. 35 and 38 are satisfied, the plate is firstpeeled off and subsequently has opposite sides cut. This causesincreased tensile strength between peeling off the plate and cutting it.Consequently rupture occurs and a beveled geometry results. By adjusting∠YOA and ∠YOB, different degrees of beveling can be selected.

Furthermore for this liquid crystal panel 150 sealing agent 103surrounds an entire perimeter of the liquid crystal layer continuously.Herein to “surround an entire perimeter continuously” means that aperimeter is surrounded completely without discontinuity by anenclosure.

Furthermore, for this liquid crystal panel 150, as shown in FIG. 20,glass substrates 101 a and 102 a do not completely overlap. Glasssubstrate 101 a alone protrudes to provide a terminal portion 109 forconnection of FPC 108. Terminal portion 109 is also provided withpolarizing plate 106 a extending on a surface of glass substrate 101 aopposite the liquid crystal layer, i.e., a surface opposite that towhich FPC 108 is connected.

FPC 108 can be connected by thermal compression bonding. However, theheat applied can deform or discolor polarizing plate 106 a located on asurface opposite to that having FPC 108 connected thereto. To addressthis, as shown in FIG. 26, polarizing plate 106 a may be removed betweena region corresponding to a rear side of terminal portion 109 having FPC108 connected thereto and the liquid crystal panel's display area toprovide a region for separation 118 to prevent heat applied to terminalportion 109 from being transferred through otherwise existing,underlying polarizing plate 106 a and thus negatively affecting thedisplay area. Furthermore, as shown in FIG. 27, terminal portion 109 mayhave a rear region completely free of polarizing plate 106.

While FIGS. 20 and 21 exemplarily show a structure with two glasssubstrates both provided with polarizing plate 106 a, for some system,aim and the like of the liquid crystal panel, only one of the glasssubstrates may be provided with the polarizing plate.

Note that while in each embodiment the substrate has been described as a“glass substrate,” the substrate is not limited to a glass substrate andmay be formed of a different material.

In accordance with the present invention in fabricating a liquid crystalcell and sticking a polarizing plate a large format substrate includinga plurality of liquid crystal cells can exactly be used to collectivelydo so. This can provide a reduced period of time required for per liquidcrystal panel so as to effectively produce liquid crystal cells.

Fourth Embodiment

FIG. 40 represents a concept of one example of an apparatus sticking apolarizing plate in accordance with the present invention. FIG. 41 is aside view of the apparatus. With reference to FIGS. 40 and 41, apolarizing plate sticking apparatus 1 a includes: a holding means 60holding a roll 10 of a polarizing plate 15 a formed in a strip; a pressdie 80 serving as a means cutting continuously pulled and thus unrolledpolarizing plate 15 a to match a geometry of a liquid crystal substrate30; and a head 100 serving as a means sticking cut polarizing plate 15 aon liquid crystal substrate 30.

Roll 10 is a roll of a combination 15 of a separator 15 c serving as asupport and a polarizing plate 15 b formed thereon. Press die 80 cutspolarizing plate 15 b alone and does not cut separator 15 c.

Apparatus 1 a further includes a detector 50 serving as a meansdetecting an axis of polarization of polarizing plate 15 b unrolled.Press die 80 is driven by an axis of polarization detected by detector50 to adjust a direction followed to cut polarizing plate 15 b.

Press die 80 cuts polarizing plate 15 b to have substantially the samesize as liquid crystal substrate 30. Press die 80 includes a pressmeans.

A reel 61 is attached to holding means 60 and combination 15 is woundaround reel 51 to form roll 10. Polarizing plate 15 b in combination 15is fed from roll 10 and before polarizing plate 15 b is taken up by atake-up roll 20 detector 50 initially detects an axis of polarization.In accordance with the direction of the axis of polarization press die80 is adjusted to have an angle for cutting the polarizing plate, andmoves in a direction 81 to provide polarizing plate 15 b with anincision 15 d to cut (half cut) polarizing plate 15 b to provide cutpolarizing plate 15 a. In doing so, separator 15 c is not cut. Press die80 is arranged to have an inclination for example of 45° relative to adirection of unrolled polarizing plate 15 b. Press die 80 is set at adesired angle to accommodate the model of interest.

Detector 50 detects a direction of an axis of polarization of polarizingplate 15 b. Detector 50 is configured of a light emitting portion, alight receiving portion, and a single sheet of polarizer (not shown).The polarizer is rotated to vary an amount of light passing throughpolarizing plate 15 b and the polarizer. This variation is detected todetect an axis of polarization of polarizing plate 15 b.

Polarizing plate 15 a cut by press die 80 is sucked by head 100 on asuction platform 10 b through vacuum. As it moves past a peeling roller25, cut polarizing plate 15 a alone is separated from separator 15 c.After it is completely peeled off separator 15 c, polarizing plate 15 asucked by head 100 is moved to a polarizing plate sticking stage 110, asindicated by an arrow B, and placed on large format, liquid crystalsubstrate 30. Then polarizing plate 15 a has an end pressed by a roller100 a of head 100 and stage 110 moves in a direction A to stickpolarizing plate 15 a on liquid crystal substrate 30. To stickpolarizing plate 15 a on liquid crystal substrate 30 with highprecision, polarizing plate 15 and liquid crystal substrate 30 placed onstage 110 are joined together after on head 100 polarizing plate 15 ahas an end surface brought into contact with a jig (not shown) tomechanically position the same.

Note that if separator 15 c and polarizing plate 15 b are completelycut, rather than half cut, on head 100 separator 15 c needs to be peeledoff by means of an adhesive tape or the like. Peeling roller 25 may bereplaced with a flat member, although a roller is desirable since onseparator 15 c the polarizing plate rolled still remains.

Thus the present invention in the fourth embodiment provides polarizingplate sticking apparatus 1 a that allows press die 80 to cut polarizingplate 15 b in a geometry corresponding to liquid crystal substrate 30and then immediately sticks cut polarizing plate 15 a by means ofpolarizing plate sticking head 100. This eliminates the necessity ofinitially cutting a polarizing plate in an elongate geometry asconventional. The polarizing plate can be stuck on the substrate moreefficiently.

When an elongate polarizing plate is stuck directly on liquid crystalsubstrate 30, as conventional, the polarizing plate is stuck on aportion which does not require it. Accordingly, it needs to be cut toprovide a determined geometry. In accordance with the present inventionthe polarizing plate can be cut only once to correspond to a geometry ofliquid crystal substrate 30. The polarizing plate can be stuck only at adesired portion. Furthermore, a reduced number of cutting steps can beprovided to stick the polarizing plate more efficiently. Furthermore,the polarizing plate can efficiently be utilized.

Fifth Embodiment

FIG. 42 is a side view of an apparatus sticking a polarizing plate inaccordance with the present invention in a fifth embodiment. Withreference to FIG. 42, the present invention in the fifth embodimentprovides a polarizing plate sticking apparatus 1 b including a cuttingmeans formed of a linear blade 180 cutting a polarizing plate. Blade 180is attached to a head 200 serving as a means sticking cut polarizingplate 15 a on liquid crystal substrate 30.

In the fourth embodiment a longitudinal direction of polarizing plate 15b in a strip and a direction of an axis of polarization of polarizingplate 15 b in the strip are parallel to each other. To allow each sideof cut polarizing plate 15 a and an axis of polarization of cutpolarizing plate 15 a to form an angle of 45°, in the fourth embodimentan inclination of 45° is introduced in cutting polarizing plate 15 b. InFIG. 42, unrolled polarizing plate 15 b has an axis of polarizationpreviously inclined for example by 45° relative to the longitudinaldirection of unrolled polarizing plate 15 b. This eliminates thenecessity of inclining blade 180 to cut polarizing plate 15 b, andpolarizing plate 15 a thus cut can be stuck on liquid crystal substrate30. In FIG. 42, polarizing plate 15 a is not required to haveinclination relative to liquid crystal substrate 30 and can be stuckthereon vertically.

Polarizing plate 15 b in the form of a strip is fed from roll 10 and hasa direction of an axis of polarization thereof detected by detector 50.Then, polarizing plate sticking head 200 is positionally adjusted. Head200 has a press roller 200 a and a suction platform 200 b and by suctionplatform 200 b polarizing plate 15 b is sucked and held. Polarizingplate 15 b thus sucked is cut on a cutting stage 185 straight by blade180 provided integral to head 200. In this case, as well as in thefourth embodiment, separator 15 c is not cut, i.e., half-cutting isperformed.

Thereafter, similarly as has been described in the fourth embodiment,polarizing plate 15 a sucked on head 200 is separated from separator 15c as it moves past a peeling member 26. Polarizing plate 15 a is placedon a liquid crystal substrate 30 provided in the form of a large sizesubstrate and placed on stage 110. The head 200 roller 200 a presses anend of polarizing plate 15 a and stage 110 moves in a direction A tostick polarizing plate 15 a on liquid crystal substrate 30.

This apparatus allows polarizing plate sticking head 200 and polarizingplate cutting blade 180 to be integrated together. As such, a polarizingplate adapted for a large size substrate can be cut by the apparatushaving a reduced size.

As head 200 is positionally aligned, polarizing plate 15 a is stuck onliquid crystal substrate 30 obliquely. However, such is not particularlydisadvantageous as the polarizing plate has an axis of polarization witha direction adapted for liquid crystal substrate 30.

Polarization sticking apparatus 1 b of the present invention in thefifth embodiment is as effective as polarizing plate sticking apparatus1 a of the invention in the fourth embodiment.

Sixth Embodiment

FIG. 43 is a side view of the polarizing plate sticking apparatus of thepresent invention in a sixth embodiment. With reference to the figure,the sixth embodiment provides a polarizing plate sticking apparatus 1 cincluding: a blade 250 serving as a means cutting in a geometry ofliquid crystal substrate 30 polarizing plate 15 b continuously unrolledand extracted from roll 10; and head 300 serving as a means sticking cutpolarizing plate 15 a on liquid crystal substrate 30.

In apparatus 1 c, polarizing plate 15 b sent from roll 10 has adirection of an axis of polarization detected by detector 50. Note thatthis direction of the axis of polarization is similar to that in thefifth embodiment. Polarizing plate 15 b is cut by blade 250 on a cuttingstage 255 and sent by separator 15 c.

After it has moved past a peeling member 27, polarizing plate 15 a willmove straight ahead by its rigidity. However, a guide roller 280 guidesthe polarizing plate slightly downward. The polarizing plate is guidedas it slides under head 300 on a surface of a suction platform 300 b andmoves past under a press and contact roller 300 until it is detected bya position detection sensor 300 c. In doing so, stage 110 is moved tojoin liquid crystal substrate 30 mounted thereon and polarizing plate 15a together. By moving stage 110 in a direction A, polarizing plate 15 acan be stuck on liquid crystal substrate 30. Note that by rotating stage110 in accordance with a direction of an axis of polarization detected,polarizing plate 15 a can be stuck in accordance with an axis ofpolarization suitable to liquid crystal substrate 30.

As described above, the present invention can provide an apparatus thatcan stick a polarizing plate on a liquid crystal substrate collectivelyand hence efficiently. As a result, the cycle time and the number ofapparatuses can significantly be reduced.

The embodiments disclosed herein should be considered in all terms asillustrative, not limitative. The scope of the present invention isdefined only by the attached claims, not by the description above, andis intended to encompass all modifications within the meaning and scopeof the claims and equivalents.

INDUSTRIAL APPLICABILITY

The present invention can achieve a significant contribution infabricating a large number of liquid crystal panels when it is appliedto the process for fabricating the liquid crystal panels. Furthermorethe present invention is useful in the process in improving theefficiency of the step of sticking a polarizing plate at a desiredportion.

Although the present invention has been described and illustrated indetail, it is clearly understood that the same is by way of illustrationand example only and is not to be taken by way of limitation, the spiritand scope of the present invention being limited only by the terms ofthe appended claims.

1-5. (canceled)
 6. A method of fabricating a liquid crystal panel,comprising the steps of: placing a sealing agent on a surface of a firstsubstrate in a form of an enclosure; introducing liquid crystal on saidfirst substrate in a region enclosed by said sealing agent or on asecond substrate in a region corresponding to said region located onsaid first substrate enclosed by said sealing agent; sticking said firstsubstrate and said second substrate together to form a substrate formedof said first substrate and said second substrate; sticking a polarizingplate on at least one of said first substrate and said second substrateso said substrate includes the polarizer plate on at least one of saidfirst substrate and said second substrate; and after said sticking,dividing said substrate with the polarizer plate(s) thereon to have ageometry providing a plurality of liquid crystal panels, each of theprovided plurality of liquid crystal panels thus having the polarizerplate on at least one of said first substrate and said second substrate.7. The method of claim 6, wherein said dividing includes partiallyremoving a portion of the polarizing plate stuck on said at least one ofsaid first substrate and said second substrate, thereby exposing asurface of said at least one of said first substrate and said secondsubstrate and dividing the substrate in the exposed surface.
 8. Themethod of claim 6, wherein the step of dividing is preceded by the stepof collectively, simultaneously inspecting more than one liquid crystalcell defined by said sealing agent, via an interconnection electricallyconnected to each said liquid crystal cell for inspection.
 9. The methodof claim 8, wherein the step of inspecting is performed after the stepof overlaying and before the step of sticking.
 10. The method of claim8, wherein the step of inspecting is performed after the step ofsticking.
 11. The method of claim 6, further comprising the step ofexposing a terminal portion provided at one of said first and secondsubstrates.
 12. The method of claim 11, wherein the step of exposing isperformed in the step of overlaying by displacing said substrates fromeach other.
 13. The method of claim 11, wherein the step of exposing isperformed after the step of overlaying by dividing and partiallyremoving one of said substrates. 14-21. (canceled)